(with specialization in cotton ginning) 1-year … · (with specialization in cotton ginning)...
TRANSCRIPT
CURRICULUM FOR
FITTER GENERAL
(WITH SPECIALIZATION IN COTTON GINNING)
1-YEAR
(Diploma course)
National Vocational & Technical Training Commission, Islamabad (February, 2012)
CONTENTS
Training Objectives……………………………………………………………………………. 3
Curriculum Salient Points……………………………………………………………………. 3
Skill Competency details………………………………………………………………………. 4
Knowledge Proficiency Details………………………………………………………………. 4
Curriculum Delivery Structure………………………………………………………………... 5
Scheme of Studies……………………………………………………………………………… 6
Detail of Course Contents…………………………………………………………………….. 7
List of Tools / Machinery / Equipments…………………………………………………….. 16
Employability of Pass Outs…………………………………………………………………… 21
Minimum Qualification of Instructors……………………………………………………….. 21
Reference Books………………………………………………………………………………... 22
National Curriculum & Review Committee Members…………………………………….. 23
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TRAINING OBJECTIVES
The major Objectives of this course are to:
Produce skilled workers who can carryout routine maintenance of
Cotton ginning machinery
Learn about tools, their uses, measurement, fastening method, hand
operations techniques, drill & lathe machine operations etc. along with
ethical values.
CURRICULUM SALIENT POINTS
Entry level : Middle (Preferably Matric)
Duration : 1-Year (2-Semesters)
Training hours : 1600 Hours (800 Hours/
Semester)
40 Hours per week
7 Hrs per day (Friday 5 Hours)
Training Methodology : Practical 80%
: Theory 20%
Medium of Instruction : Urdu / English
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SKILL PROFICIENCY DETAILS After successful completion of this course, the trainee should be able to:
1. Use measuring tools & fitting tools
2. Sketch and draw different work diagrams and views of an object
3. Prepare jobs on lathe machine
4. Drill different size of holes on drill machine
5. Perform bench & maintenance work
6. Observe safety rules and precautions relating to ginning machinery
7. Carry out replacement of gin saws and ribs and their adjustments
8. Apply shutdown procedure
KNOWLEDGE PROFICIENCY DETAILS After successful completion of this course the trainee will have the knowledge
about:
1. Safety precautions and measures pertaining to the trades
2. The basic mathematics.
3. The reading of measuring & checking tools.
4. The name, identify hand tools, fitting tools and maintenance tools.
5. Safety precautions for bench work
6. The lathe machine (introduction, parts and operations)
7. The drill machine (introduction, parts and operations)
8. Identification of different materials
9. Basic drawing
10. Introduction of workshop items, tools and machine parts, mounting
and dismounting of bearing, gears, pulleys and sprockets
11. Function and standardized setting of gin saws (teeth) of ginning
machine
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CCUURRRRIICCUULLUUMM DDEELLIIVVEERRYY SSTTRRUUCCTTUURREE
1ST SEMESTER
Course Delivery Co Curricula Activities /
Vacations Test Total
Week
1-20 21-25 26
26
20 5 1
2ND SEMESTER
Course Delivery Co Curricula Activities /
Vacations Final Test Total
Week
1-20 21-25 26
26
20 5 1
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SCHEME OF STUDIES Fitter General
(1-Year Course)
1ST SEMESTER
Sr. No.
Main Topics Theory Hours
Practical Hours.
Total Hours
1. Introduction of workshop, workplace and tools
09 20 29
2. Measuring-1 14 80 94
3. Hand Operation Techniques – I 21 320 341
4. Drill Machine Operation Techniques 18 120 138
5. Fastening Methods (Riveting) 18 80 98
6. Technical Math – I 20 - 20
7. Technical Drawing – I 20 - 20
8. Functional English 40 - 40
9. Work Ethics - 20 20
Total 160 640 800
2ND SEMESTER
Sr. No.
Main Topics Theory
Hrs. Practical
Hrs. Total Hrs.
1. Measuring- II 10 60 70
2. Temporary Fastening Methods 14 60 74
3. Lathe Machine Operations 20 150 170
4. Hand Operation Techniques -II 15 270 285
5. Materials (Iron + Steel) 10 - 10
6. Technical Math – II 15 - 15
7. Technical Drawing – II 16 - 16
8. Introduction to Ginning (Allied Training)
12 56 68
9.
Ginning Machinery Model Layout & Its Operational Maintenance Requirements – I
8 24 32
10. Functional English 40 - -
11. Work Ethics - 20 20
Total 160 640 800
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DETAIL OF COURSE CONTENTS
Fitter General (1-Year Course)
1ST SEMESTER
Sr. No.
Detail of Topics Theory Hours
1. Introduction of workshop, workplace & tools
1.1. Workshop, workplace, safety precaution (general)
1.2. Characteristics of metal
1.3. Workshop tools
1.4. Power : Machine power
Muscular power
03
02
02
02
2. 2. Measuring –I
2.1. General introduction
2.2. System of Units (FPS & MKS System)
2.3. Calipers – gauges
2.4. D-Type Bevel Protractor and spirit level
2.5. Vernier caliper
2.6. Care and safety precautions of instruments
02
01
04
02
04
01
3. 3. Hand Operation Technique I
3.1. Marking, Letter & Number Punching (Straight & Angular)
3.2. Chipping and cutting
3.3. Sawing
3.4. Chiseling
3.5. Shearing
3.6. Filing
3.7. Scraping
3.8. Tapping
3.9. ISO fits
02
03
02
03
03
02
02
02
02
4. 4. Drill Machine Operation Techniques
4.1. Drilling (Types)
4.2. Counter sinking
4.3. Counter boring
4.4. Reaming
4.5. Die & Tapping by (hand & machine)
10
02
02
02
02
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5. 5. Fastening Methods (Riveting)
5.1. Introduction of fastening
5.2. Types of screw, nuts & bolts
5.3. Joining of parts with screw
5.4. Riveting (Types)
5.5. Standardization of thread
5.6. Size of screw, bolt and nut
5.7. Thread cutting tools
02
03
02
02
03
02
04
6. 6. Technical Math – I
6.1. Whole Number (Addition & Subtraction)
6.2. Multiplication & Division
6.3. Fraction (Addition & Subtraction of common Fractions)
6.4. Proper fraction, improper fraction mix numbers
6.5. Multiplication and division of fraction
6.6. Decimal system of measurement meter – gram – liter
6.7. Multiples and parts of units
6.8. Addition and subtraction
6.9. Multiplication and division
6.10. Conversion of FPS into MKS System
02
02
02
02
02
02
02
02
02
02
7. 7. Technical Drawing – I
7.1. Introduction to technical drawing
7.2. Drawing instruments
7.3. Kinds of lines
7.4. Lettering
7.5. Views (introduction and types)
1st & 3rd angle projection
7.6. Representation in three views
7.7. Assembling bodies
7.8. Completion of missing views visible edges
7.9. Work pieces with cover edges
7.10. Dimensioning
7.11. Draw true scale
7.12. Drawing of radial
01
01
01
02
02
02
02
02
02
01
02
02
Total 120
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2ND SEMESTER
Sr. No.
Detail of Topics Theory Hours
1. 1. Measuring -II
1.1. Introduction of micrometers (outside – inside -
depth)
1.2. Care and applications of micrometers
1.3. Reading of micrometers
1.4. Thread gauges (Metric - British)
1.5. Snap and plug gauges
1.6. Gauge blocks
1.7. Dial indicators
1.8. Profile gauge
02
01
02
01
01
01
01
01
2. 2. Temporary Fastening Methods
2.1. Joining of parts with nut & bolt
2.2. Types of nut and bolt
2.3. Motions and forces at threads
2.4. Representation of forces on threads by means of
drawing
2.5. Screw jack
2.6. Types of keys
03
02
02
02
02
03
3. 3. Lathe Machine Operations
3.1. Introduction of center lathe machine
3.2. Types of lathe machine
3.3. Turning operation
3.4. Turning tools
3.5. Threading operation (inside / outside)
3.6. Boring operation
3.7. Knurling operations
3.8. Taper turning
3.8.1. (Compound slide, tail stock & taper turning
attachment)
02
02
03
02
04
03
02
02
4. 4. Hand Operations Techniques -II
4.1. Bending process
01
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4.2. Bending effect
4.3. Bending tools and devices
4.4. Bending machines
4.5. Bending of pipes and sheets
4.6. Bending by hand
4.7. Bending by machine
4.8. Hammering and straightening
4.9. Stretching and up setting
4.10. Clamping
01
01
02
01
01
02
02
02
02
5. 5. Materials (iron + steel)
5.1. Introduction of metals
5.2. Characteristics of metals
5.3. Ferrous and non ferrous metals
5.4. Pure and alloy metals
5.5. Base metals
5.6. Use of grey cost iron and steel
5.7. Non ferrous metal with use
5.8. Properties of metals & Elementary metals alloys
5.9. Crystal structure of metals
5.10. Hardness of material
01
01
01
01
01
01
01
01
01
01
6. 6. Technical Math – II
6.1. Angle units (degree –minutes - second)
6.2. Conversion of degrees into minutes and seconds
6.3. Calculation of angles, addition – subtraction –
multiplication –division
6.4. Calculation of tolerance
6.5. Calculation of maximum and minimum size
6.6. Calculation of surface area
02
02
03
03
03
02
7. 7. Technical Drawing – II
7.1. Inclined surface
7.2. Cylindrical work pieces
7.3. Centerline dimensioning
7.4. Draw three views
7.5. Surface symbols
7.6. Assembling of two parts
7.7. Tolerance (entry of tolerance in drawing)
02
02
02
02
02
02
02
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7.8. Measuring of sizes 02
8. 8. Introduction to Ginning ( Allied Training)
8.1. Introduction of ginning operation its requirements &
essentials.
8.2. History & development of ginning techniques.
8.3. Modernization of ginning techniques processes,
induction of special equipment to improve their working
efficiencies.
8.4. Common standard types of ginning processes used in
Pakistan i.e. roller ginning, saw ginning etc.
8.5. Description of roller ginning process. Its merits &
demerits, limitations.
8.6. Explanation of saw ginning process its merits demerits,
preferences
8.7. Comparison of saw & roller Ginning processes.
1
1
2
2
2
2
2
9. 9. Ginning Machinery Model layout & its operational
maintenance requirements – I
9.1. Requirement & types of maintenance i.e. routine,
periodic & scheduled maintenance. Special overhauling,
emergency repair etc.
9.2. Daily, weekly & monthly checking of shafts, bearings &
oil level of various points etc.
9.3. Basic Machine elements and their pairs, assembling-
disassembling i.e. shaft & pulleys gears, sprockets &
chains, their types & fitting techniques use of gear puller
etc.
3
3
2
Total 120
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DETAIL OF COURSE CONTENTS
Fitter General
(1-Year Course)
1ST SEMESTER
Sr. No
Detail of Topics Practical
Hours
1. 1. Introduction to Work Bench Tools
1.1. Uses of workshop tools
02
2. 2. Work Bench Tools
2.1. Files – steel rule –scriber
2.2. Centre punch
2.3. Hammers – chisel – hacksaw
2.4. Scraper
2.5. Number & Letter Punch Set
(Removal of Tri Square)
18
3. 3. Basic Measurement
3.1. Application of steel rule (Metric+ British)
3.2. Application of vernier caliper (Depth caliper)
3.3. Application of Tri square
3.4. Application of bevel protector
3.5. Application of outside caliper
3.6. Application of inside caliper
3.7. Application of steel tap
3.8. Calculation of center distance of holes
3.9. Application of work bench tools
08
08
16
08
08
06
18
08
4. 4. Hand Operation Techniques I
4.1. Filling exercise
4.2. Marking exercise (Letter & Number Punch Set)
4.3. Stretching exercise
4.4. Sawing exercise
4.5. Filling of thin & thick work pieces
4.6. Filling of sheet metal
4.7. Riveting exercise
4.8. Chipping exercise
320
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4.9. Shearing exercise
4.10. Tapping exercise
4.11. Simple assembling
5. 5. Drill Machine Operations
5.1. Application of drill
5.2. Exercise of drilling blind hole
5.3. Exercise of drilling through hole
5.4. Exercise of drilling counter sinking
5.5. Exercise of drilling counter boring
5.6. Exercise of reaming
5.7. Exercise of tapping
5.8. Exercise of drilling use of clamping devices in
drilling operations
(5.1 Word “Work” deleted)
120
6. 6. Fastening Methods
6.1. Application of fasting (Riveting)
6.2. Exercise of external threads
6.3. Exercise of joining of parts with screws and pins
6.4. Exercise of joining of parts with rivets
88
Total 620
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2nd SEMESTER
Sr. No
Detail of Topics Practical
Hours
1. 1. Measuring – II
1.1. Application of micrometers
1.2. Practice of outside micrometer
1.3. Practice of inside micrometer
1.4. Practice of depth micrometer
1.5. Care of micrometers
1.6. Application of gauges
1.7. Practice of thread gauges
1.8. Practice of snap gauges
1.9. Practice of plug gauges
1.10. Practice of gauge blocks
1.11. Practice of dial indicators
1.12. Practice of universal bevel protractor
1.13. Practice of spirit level
04
04
05
05
02
02
04
04
04
06
06
10
04
2. 2. Temporary Fastening Methods
2.1. Practice of joining nut & bolts
2.2. Application of screws
2.3. Exercise of center square
2.4. Exercise of tap handles
2.5. Exercise of punch fitting
2.6. Exercise of fitting hacksaw frame
2.7. Exercise of fitting rocker arm
2.8. Exercise of fitting table lamp
06
06
08
08
08
08
08
08
3. 3. Lathe Machine Operations
3.1. Application of centre lathe
3.2. Turning operation exercise
3.3. Taper turning operation exercise
3.4. Threading operation exercise
3.5. Boring operation exercise
3.6. Exercise of bolt
150
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3.7. Exercise of step bolt
3.8. Exercise of conical work piece
3.9. Exercise of locking spindle and pressure discs
3.10. Exercise of taper turning
4. 4. Hand Operation Techniques II
4.1. Application of square fitting
4.2. Exercise of dove tail fitting
4.3. Exercise of fitting of different parts
4.4. Exercise of preparing table lamp
270
5. 5. Ginning processes
5.1. Exercise of ginning operations.
5.2. Exercise of ginning techniques.
5.3. Demonstration of modern and special equipment.
5.4. Exercise of Roller and Saw Ginning.
(The theory questions are transferred into
practical and 5.5 to 5.7 are deleted & their
numbers are added above)
16
16
16
08
6. 6. Ginning Machinery Model layout & its operational
maintenance requirements -I
6.1. Practice of different types of requirement of
maintenance i.e. routine, periodic & scheduled
maintenance. Special overhauling, emergency
repair etc.
6.2. Daily, weekly & monthly checking of shafts,
bearings & oil level of various points etc.
6.3. Basic Machine elements and their pairs,
assembling-disassembling i.e. shaft & pulleys
gears, sprockets & chains, their types & fitting
techniques use of gear puller etc
8
10
6
Total 640
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LIST OF TOOLS / MACHINERY / EQUIPMENT
(For the class of 25 students)
Sr. No Equipment / Tools Quantity
1. Work Bench with vice 5” 25 Nos. each
2. Flat File;
300*1
250*1
200*1
150*1
250*3
200*3
150*3
25 Nos.
25 Nos.
25 Nos.
25 Nos.
25 Nos.
25 Nos.
25 Nos.
3. Half Round File;
250*1
250*3
200*1
200*3
150*1
150*3
25 Nos.
25 Nos.
25 Nos.
25 Nos.
25 Nos.
25 Nos.
4. Round File;
200*1
200*3
150*1
150*3
25 Nos.
25 Nos.
25 Nos.
25 Nos.
5. Square File;
200*1
200*3
150*1
150*3
25 Nos.
25 Nos.
25 Nos.
25 Nos.
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6. Triangle files;
200*1
200*3
150*1
150*3
25 Nos.
25 Nos.
25 Nos.
25 Nos.
7. Try Square 100x150mm 25 Nos.
8. Steel Rule 12” 25 Nos.
9. Vernier Caliper 160mm (6”) 25 Nos.
10. Line scriber (Double edge) 25 Nos.
11. Center punch 100mm 25 Nos.
12. Back square 100 x 150 mm, 25 Nos.
13. Flat chisel 150mm 25 Nos.
14. Grove cut chisel 25 Nos.
15. Cross cut chisel 150mm 25 Nos.
16. Spring divider 6” 25 Nos.
17. Bench hammer 500 grams (Cross pin) 25 Nos.
18. Bench hammer 300 grams (Cross pin) 25 Nos.
19. Hack saw frame 12” (Haw deleted) 25 Nos.
20. Dust brush, File Brush (Each) 25 Nos.
21. Flat scraper 12” 12 Nos.
22. Half Round scraper 8” 12 Nos.
23. Key file set (set of 6 pieces) 12 Nos.
24. Needle file set (set of 100x 12 pieces) 12 Nos.
25. Drill set 1 to 10 mm fraction 0.1 10 sets.
26. Drill set 1 to 13 mm fraction 0.5 10 sets
27. Reamer also set 3H7, 4 H7, 5H7, 6H7, 8H7, 10H7, 12H7,
14H7, 16H7 with drill 10 Nos. each
28. Adjustable reamer ¼ to 1 ½ “ 2 sets
29. Tap set M3 to M20 3 sets
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30. Die set M3 to M20 3 sets
31. Tap handle 0, 1, 2 No. 10 Nos. each
32. Tap extractor 6 sets
33. Screw extractor 6 sets
34. Hand vice 6” 10 Nos.
35. Oblique clamp 6” 10 Nos.
36. Screw driver 10”, 8”, 6”, 4” 5 Nos. each
37. Master tri square 100 x 150 & 150 x 200 5 Nos. each
38. Straight edge 100 & 150 5 Nos.
39. Tap extension M4, M5, M8, M6, M10 4 Nos. each
40. Rivet forming tools 3, 4, 5, 6, 8 6 sets
41. Rivet cleaning set 3, 4, 5, 6, 8 6 sets
42. Combination pair 6”, 8” 6 Nos.
43. D type bevel protractor 6 Nos.
44. Universal bevel protractor 2 Nos.
45. Radius gauge 1 to 7 mm 6 Nos.
46. Wooden melt 6 Nos.
47. Aluminum melt 6 Nos.
48. Sledge hammer 5 kg 2 Nos.
49. Hand shear (straight) 8” 6 Nos.
50. Micrometer 0-25 & 25-50, 50-75 (2 Each) 6 Nos.
51. Oil cane (Pump type) 8 Nos.
52. Shaper machine with accessories, 14” 2 Nos.
53. Pedestal Grinder machine 8” Wheels 2 Nos.
54. Bench drill machine with accessories 2 Nos.
55. Piller drill machine with accessories 1” Dia 2 Nos.
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List of Machinery / Equipment For Cotton Ginning Lab
(For the Class of 25 Students)
The following machinery / equipment etc. would be required for effective and comprehensive training of the trainees at the institute level / their timely modifications, improvements and innovations are also recommended. Miniature sectional working models of plants machinery/ equipment are preferred. Sr. No.
Nomenclature of Equipments / Tools Quantity
1 Seed Cotton Cleaning And Ginning Plant (Live) One complete set
2 Condenser along with all accessories 1 No.
3 Cleaning Module consisting on: -
i. Rock catcher with all accessories of different nos. 1 No.
ii. Separator (with Vacuum Box) and all accessories 1 No.
iii. Flat cleaner 1 No.
iv. Incline cleaner with all accessories. 1 No.
v. Stick machine with all accessories 1 No.
vi. Feeder extractor cleaner (FEC) 1 No.
vii. Belt conveyor with all accessories 1 No.
viii. Screw conveyer with all accessories 1 No.
ix. Dust collector (Cyclone) 1 No.
x. Lint cleaner 1 No.
xi. Fan / blowers 2 Nos.
xii. Ducts 10 Nos.
xiii. Plate valves 10 Nos.
xiv. Dragon machine 1 No.
xv. Suction Fan with all accessories 1 No.
4 Ginning Module:-
i. Saw ginning machine (Gin-stand) with all
accessories of different nos. and spare parts.
1 No.
ii. Gin saws 20 Nos.
iii. Ribs (various sizes and designs) 40 Nos.
iv. Roller ginning machine 1 No.
5. Packing Module:-
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i. Hydraulic press 1 set
ii. Hydraulic pump station 1 No.
iii. Baling unit 1 set.
iv. Weighting unit 1 set.
6 Over Head Crane 5 Ton 1 No.
7 Fork Lifter 5 Ton 1 No.
8 Power Saw Machine with accessories 1 No.
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EMPLOYABILITY OF PASS OUTS
The pass out of this course can find job / employment in the following areas /
sectors: -
1. HMC Taxila
2. Atomic Energy Commission
3. Packages Ltd. Lahore
4. Refrigeration & Air Conditioning Industry
5. Cycle Industry
6. Mechanical repairing workshops
7. Any seasonal Cotton Ginning Factory
8. Steel Mill
9. Oil Refineries
10. Railway Locomotive Sheds (Workshop)
11. Textile Industries
12. All industries in Pakistan
MINIMUM QUALIFICATION OF INSTRUCTOR
DAE in (Mechanical Technology) with two years industrial
experience.
OR
Two years proficiency certificate of Fitter General or Fitter
Millwright with six years relevant experience.
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REFERENCE BOOKS
Manual on metallurgy II-year mechanical
Manual on workshop practice-II mechanical technology NISTE-
Islamabad.
Gear ling about machine tools
Fundamental of metal trade
Ginning Manual
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NAMES OF NATIONAL CURRICULUM & REVIEW
COMMITTEE MEMBERS
Their names, designations, positions and cell numbers are shown below:
Sr # Name Sr # Name
1 S.M. Wasi Zaidi, Associate Professor (Mechanical), P.S.I.T. Landhi, Karachi Cell # 0301-2847825
2 Engr. Muhammad Arshad, Principal, Government Technical Training Institute, Gulberg, Lahore Cell # 0333-4330778
3 Engr. Ghulam Abbas Channa, Principal, Govt. Polytechnic Institute, Asu Goth, Malir, Karachi Cell # 0300-7012344
4 Liaqat Ali Jamro, Deputy Director (M&E), TEVTA, Gulshan-e-Iqbal, Block 6, St. 19, Near NIPA, Karachi Cell # 0333-2606334
5 Asif Quddus, Senior Instructor, Technical Training Centre, Quetta Cell # 0333-7929275
6 Nasir Ahmed, Chief Instructor (Mechanical), Govt. Technical Trg. Institute, Gulberg, Lahore Cell # 0333-4287063
7 Muhammad Mumtaz, Senior Instructor, Govt. Technical Training Institute, Mirpur, Azad Kashmir Cell # 0346-5170024
8 Abdul Jabbar Kasi, Instructor, Technical Training Centre, Quetta Cell # 0321-8007928
9 Qaisra Sheikh, C/o General Industries, Lahore